Siding element and process of making same



s. P MILLER SIDING ELEMENT AND PROCESS OF MA July 14, 1936.

KING SAME Filed June 14, 1933 INVENTORA Siva/"7* Mf/ler BY l ATTORN EYPatented July 14, 1936 SIDING ELEBIENT AND PROCESS OF MAKING SAME StuartParmelee Miller, EnglewootL'N. J., assignor to The Barrett Company, NewYork, N. Y., a corporation of New Jersey Application June 14, 1933,Serial No. 675,777

11 Claims.

This invention is directed to siding elements and more particularly tosiding elements of the other surfaces.

felt base type coated with waterproofing material and surfaced withgranular material. The term siding elements is usedin a broad sense andis intended to include shingles or other eleselves.

Another object of this invention is to provide weather resistant andlight weight siding elements in which carbonaceous material, such as Iground coke, is used for surfacing the top and/or the under side of acoated base, thus resulting in a lighter and more durable element ascompared with the well known mineral surfaced elements.

Other objects and advantages will appear from the following detaileddescription of my invention.

It has been proposed to manufacture felt base siding elements bycoacting both sides of a bitumen-saturated felt base with bituminouscoating material, such as asphalt, partially embedding mineral grit,such as crushed slate, in the coating on both sides of the element, andthereafter applying a second coating of bituminous material and a secondsurfacing of mineral grit on that portion of the element adapted to beexposed to the weather.

In accordance with a preferred form of my invention carbonaceoussurfacing material may be employed for covering.the seal-back coatingcordingly, the siding elements of my invention' are much more weatherresistant than elements heretofore made and provide a more durable andlasting. structure. Furthermore, the bituminous coating material inwhich the coke particles are embedded tends to enter the numerous poresand crevices in the carbonaceous particles and become firmly bondedtherewith. Hence a lasting bond between the bituminous coating layer andthe carbonaceous surfacing material results.

A substantial economy is effected by the use of carbonaceous material,such as ground coke, since it is considerably cheaper than the mineralgrit heretofore used. Furthermore, carbonaceous material such as groundcoke is considerably lighter in weight than mineral granules and resultsin economies in the shipping, handling, and application of the elements.

For a better understanding of the invention reference should be made tothe accompanying drawing wherein is shown by way of illustration 2;preferred embodiment of the invention and in which:

Fig. 1 is a side elevation, somewhat diagrammatic in character, andshows the steps involved in the manufacture of the siding elements ofthis invention;

Fig. 2 is a fragmentary plan view of the first coating and surfacingapparatus, a portion of the sheet being shown in plan for the sake ofclearness;

Fig. 3 is a fragmentary plan view of the second coating and surfacingapparatus showing a portion of the coated and surfaced sheet;

Fig. 4 is a fragmentary plan view of a finished coated and surfacedsheet and indicates the layout for cutting the sheet into individualelements;

Fig. 5 is a plan view of a siding element and. illustrates a preferredembodiment of this invention;

Fig. 6 is a vertical section taken along the line 66 of the sidingelement of Fig. 5; and

Fig. '7 is a fragmentary'plan view of a number of overlapping courses,each composed of siding elements of this invention laid in abuttingrelationship. I

Referring to the drawing, with particular reference to Fig. 1, a sheetof fibrous material I, which utilized for the impregnation andsaturation of roofing felts.

Rolls I and 8 feed the saturated sheet to a second looping device 9. Thepassage of the saturated fibrous sheet or base through the loopingdevice 9 gives the saturant an opportunity to dry and to thoroughlyimpregnate the base. Rolls II and I2 feed the saturated sheet from thelooping device 9 to the coating applicance indicated generally by thereference numeral l3 having a pair of coating rolls I4 and i5. Feedrolls I2 are preferably driven at substantially the same averageperipheral speed as the coating rolls l4 and IS. A sufficient amount ofslack should be provided and maintained between the driven rolls I2 andguide rolls [6 over which the sheet passes before entering the bite ofthe coating rolls l4 and I5 to prevent tearing of the sheet if the rateof rotation of coating rolls l4 and I5 should momentarily increaserelatively to the rate of rotation of rolls l2. Coating roll I5 isrotatably mounted in a tank I! which may contain bituminous material,such as asphalt or other cementitious waterproofing substance, suitablefor coating roofing felt.

As the sheet I passes between coating rolls I4 and I5, the under side ofthe sheet is completely coated by roll 15. Waterproofing material isapplied to the top of the sheet before passing through the coating rollsby means of a supply pipe l8 equipped with a discharge spout IQ of awidth approximately equal to that of the sheet, as shown in Fig. 2. Thecoating material is spread uniformly over the top and bottom surfaces ofthe sheet as it passes between the coating rolls l4 and I5 in the formof a top coating layer 20 and a rear or seal-back coating.

Immediately after leaving the coating appliance l3 and while the coatingmaterial is still soft and tacky, the coated sheet passes under asurfacing device or hopper 22 extending across the width of the sheet.carbonaceous material, such as ground coke, is fed into this hopper andis showered by means of the usual distributing roll 23 onto the coatedbase passing thereunder covering substantially the entire surface of thesheet with surfacing material.

After being surfaced, the sheet passes about reversing roll 25 whichfunctions to partially embed the ground coke in the tacky and plasticcoating. Any excess coke granules fall from the surfaced sheet intohopper 22 from whence they were showered onto the coated sheet.

In the continued passage of the surfaced sheet, it travels next underhopper 26. Finely divided carbonaceous material such as ground orpowdered coke of a size corresponding to that of sand is deposited inhopper 26 and is discharged therefrom by distributing roll 21 onto theseal-back coating in the form of a surfacing layer coveringsubstantially the entire under side of the sheet. The sheet then passesover reversing roll 28 which partially embeds the powdered coke in thesealback coating and imparts a relatively smooth surface to the back ofthe sheet. Excess carbonaceous material falls from the sheet as thelatter passes from reversing roll 28 over a series of calendar rolls 3!)where the product is given an opcomposed of three sections as shown inFig. 3 I each of a width equal to approximately twice the width of thatportion of the finished siding element adapted to be exposed to theweather when laid. Waterproofing material from any suitable source isapplied to the top of the sheet by means of feed pipes 34 equipped withdischarge spouts 35. As shown in Fig. 3, these feed pipes and spouts arepreferably three in number and are positioned over the sheet so as tofeed the waterproofing material onto the sheet directly in front of eachsection of the coating roll 3|. The coating material discharged from thespouts is spread uniformly over the surfaced sheet in the form ofcoating lanes 36 as the sheet passes between the coating rolls.

Immediately after leaving the second coating appliance, and while thesecond coating is still soft and tacky, the sheet passes under a secondsurfacing device 38. As shown in Figs. 1 and 3, this device consists ofthree hoppers 39 each adapted to hold carbonaceous surfacing materialand each equipped with a distributing roll 40. Granular carbonaceousmaterial, such as ground coke, preferably of a different size from thegranules fed from hopper 22, is deposited in these hoppers. The materialis showered by means of the distributing rolls onto the lanes of coatingmaterial and adheres thereto forming surfaced bands 4|. The thussurfaced sheet then passes about reversing roll 42 which functions topartially embed the granules in the lanes 36 of plastic coatingmaterial. Any granules which may fall on the previously surfaced areasor bands 43 adjacent and between lanes 36 do not adhere thereto. Whenthe sheet leaves reversing roll 42 such granules and the excess granuleson the surfaced bands 4| fall therefrom back into the hoppers 39.

The double coated and double surfaced sheet next passes over a reversingroll 44 to the drying and pressing rolls 45. Feed rolls 46 feed thesheet from the pressing rolls into a looping device 41 where the productis given an opportunity to cool. From the looping device 41 the surfacedsheet passes through rolls 48 to cutting cylinders 50. These cylinderssimultaneously cut rows of slots 5| in the double coated and surfacedportions of the sheet as shown in Fig. 4. The individual slots of eachrow are of a length preferably equal to the'width of the double-surfacedbands 4|. The sheet is simultaneously cut longitudinally alonglongitudinal lines 52 intersecting the slots 5| midway between the endsthereof and also along lines 53 coinciding with the median lines of thesingle surfaced areas 43. Simultaneously with the longitudinal cuttingoperations the base is cut transversely along lines indicated by thereference numeral 54.

The transverse cuts 54 are spaced apart a dis tance corresponding to thelength of the desired elements and are of such a shape, as shown in Fig.4, that one transverse edge of each element is formed with a triangularprojection while the other transverse edge is provided with acomplemental recess. Preferably the slotting and longitudinal andtransverse cutting operations are accomplished. by passing the surfacedsheet through cutting rolls which-substantially simultaneously make allthe cuts. The cutting operations, however, may be carried out in anydesired order, the slotting operation preceding or following. thecutting of the base into longitudinal strips. From the cutting cylinders50 the cut sheet passes through knocker and ejector cylinportions of thematerial cut out to form the slots ders56, of any well known type whichremove any which may adhere to the cut sheets. From the tab ejectormechanism the individual siding elements pass to suitable stackingappliance (not shown).

The siding resulting from the above described operations is shown inFigs. 5 and 6. That portion of each element adapted to be exposed to theweather when laid is provided with a series of cut outs or slots 51defining a plurality of rectangular shaped tabs 58. Side edge 59 isformed with a triangular projection 60 and the other side edge 6| has acomplemental triangular recess 62. Each element consists of a felt base63 having a seal-back coating 64 of bituminous water-proofingcomposition, such as asphalt, rendered non-cementitious by theapplication thereto of an overlying layer 65 of powdered or groundcarbonaceous material, such as ground coke. The top side of the element,is substantially completely covered by coating layer 61 having asurfacing layer 68 of carbonaceous material partially embedded therein.covers both the tabs and the body portion of the element. A secondcoating 69 of waterproofing composition overlies the surfacing on thetabs and has a surfacing layer T0 of carbonaceous material partiallyembedded in its surface.

The element of Figs. 5 and 6 is designed to be laid in overlappingcourses with the triangular projection 60 snugly fitting within therecess 62 of a contiguous element in the same course as shown in the topcourse of Fig. '7. Hence, the triangular projection and complementaltriangular recess aid in aligning the elements in each course.

The elements are preferably so laid that the forvward edges of theelements of one course lie a short distance above the upper edges of thedouble-surfaced tabs of the elements in the next underlying course. Theresultant arrangement of the elements presents an appearance of a brickwall as shown in Fig. 7.

ering influences. The carbonaceous granules become firmly embedded inand attached to the coating material and do not become loosened in Inconnection with the foregoing description and illustration of thepreferred siding of this invention and the method of making this siding,

it should be understood that these are merely for the purpose ofclarifying an understanding thereof. Various changes and modificationsmay be made within the scope of this invention.

Although carbonaceous material ispreferably proofing material withfinely divided carbo- The surfacing layer' exclusively used in thesurfacing operations. talc,

may be used in surfacing the coating on the under side of the elementsand carbonaceous material used only in surfacing the top coating layers.Conversely, the carbonaceous material may be applied to the seal-backcoating to render it non-cementitious and the coating layers on the faceof the elements surfaced with mineral grit. Since certain other changesin carrying out the process and in the constructions set forth may bemade without departing from the scope of this invention, it is intendedthat all matter contained in the above description or shown in theaccompanying drawing shall be interpreted as illustrative and not in alimiting sense. 15

I claim:

comprises coating a felt base with cementitious waterproofing material,surfacing the waternaceous material, applying cementitious waterproofingmaterial in selected areas over the carbonaceous material on the topside of the base,

, tially embedding ground coke in said lanes, and

cutting the resultant base into siding elements. 35

3. The process of making siding elements having rectangular-tabs alongone longitudinal edge thereof which comprises coating both sides of afelt base with bituminous material, surfacing both sides of the coatedbase with ground coke, (0 applying spaced longitudinal lanes ofbituminous material over the ground coke on the top side of the base,surfacing said lanes with ground coke, cutting rows of spaced slotsthrough the surfaced lanes, and cutting'transversely through the single15 coated and single surfaced areas between the lanes and longitudinallyalong lines intersecting the rows of slots to form said elements.

4. A siding element comprising a fibrous base,

cementitious waterproofing material covering the to ,weather and undersides of the base, layers of carbonaceous material partially embedded inthe waterproofing material, a coating of waterproofing material coveringportions of the carbonaceous material on the top side of the base, 65

and a layer of carbonaceous material partially embedded in said coating.

5. A siding element comprising a fibrous base having tabs along onelongitudinal edge of the body portion thereof, the top and under sidesof 60 said base being covered with cementitious waterproofing material,carbonaceous material par tially embedded in the waterproofing materialon both sides of the base, a layer of cementitious waterproofingmaterial overlying the surfacing material on the'top side of the tabs,and carbonaceous material partially embedded in said layer ofwaterproofing material.

6. A siding element comprising a felt base having both sides coveredwith bituminous material, ground coke partially embedded in thebituminous material on both sides of the base, a layer of bituminousmaterial overlying 'the coke on the exposed portions of the base, andground 15 bituminous material.

'7. A siding element adapted to be laid with other like elements inoverlapping courses, the elements of each course being in abuttingrelationship, comprising a felt base coated on both sides withbituminous material and having tabs along one longitudinal edge thereof,said tabs being separated by slots, carbonaceous surfacing materialpartially embedded inthe bituminous material on both sides of theelement, bituminous material covering the carbonaceous surfacingmaterial on the tab portions of the element,-and carbonaceous surfacingmaterial partially em bedded in said bituminous material, the slotsbetween the tabs extending up from the lower edge of the element to adepth coextensive with the double-coated and double-surfaced portions ofcoke partially embedded in said last mentioned 9. The process of makingsiding elements which comprises coating the top side of a fibrous basewith a layer of cementitious waterproofing material, applying a layer ofground granular coke and partially embedding it in said layer ofcementitious waterproofing material, said waterproofing materialentering the pores and crevices of said coke to bond the latter firmlyto said coating layer.

10. A siding element comprising a base coated with a layer ofcementitious waterproofing material and surfaced with a layer of groundcarbonaceous material partially embedded in the layer of waterproofingmaterial, said waterproofing material entering the pores and crevices ofsaid carbonaceous material whereby firm adhesion of the carbonaceousmaterial to the waterproofing material is secured.

11. A siding element comprising a felt base provided with a seal-backcoating of cementitious 2o STUART PARMELEE MILLER.

